An improved physical demand analysis framework based on ergonomic risk assessment tools for the manufacturing industry

Abstract Most of the operational tasks in the manufacturing process entail numerous physical involvements, despite the introduction of automated equipment. Due to this high physical demand in manufacturing, the need for proactive risk assessment to decrease potential injury cannot be ignored. Physical Demand Analysis (PDA) is a widely used tool recommended to all manufactures by the Canadian Workers’ Compensation Board to document the physical, cognitive, and environmental demands of essential tasks. However, limitations exist in utilizing the content generated in current PDA practice to conduct risk identification and risk assessment, and it has limited functionality for providing modified work to proactively mitigate risk. This paper summarizes the input requirements of risk assessment tools and proposes an improved PDA form with an integrated framework to facilitate the comprehensive and intelligent use of PDA. This paper focuses on three aspects of PDA implementation—risk identification, risk evaluation, and risk mitigation—targeting the development of modified work for the manufacturing industry. The framework is implemented in a window and door manufacturing facility, and a case study of a window glazing station is described in this paper in order to assess awkward body postures. Four main ergonomic risk assessments and identifications are recommended.